What is the best way to setup and mill these features?

[NatFJ55]

I need to machine the two 1.005 diameter features so they are coaxial with each other.

Should I stand it upright and machine the 1.005 dimension all the way through the part, then remove the material in between? Do I have to flip the part and machine from the other side?

How would you guys go about it?

Thanks for the help!

[John Welden]

As always, it depends on the machines you have to work with and the kind of material the part is.

[NatFJ55]

Doh!

The part is 6061-T6 aluminum and I have a Syil X4 Plus mill, with Mach 3 and I am using Featurecam to generate toolpaths.

[Geof]

Small machine, probably not able to interpolate both semicircles from one end with a long cutter.

For one, or a small number:

My suggestion is machine the overall shape without the semicircles then grip it in a vise and do these one at a time.

It will be necessary to take care aligning it in the vise and you must make sure you use the same sides to dial it in vertical.


For many:

Get a rotary table and devise a fixture so you do not have to spend time tediously aligning the part in two operations for the semicircle.

[Boots]

I would rough out the bores to .030 undersize from either end then machine all other dim. to size. Stand it upright and finish boring the dia. with an inserted bore bar. You will need some way to inspect the part before moving it as the bores are tight. Unless you put stops on your vice/table so the part will repeat if removed.

[flick]

If it's just aluminum I think you can bore/interpolate it from one end.

Or, if there's only one or two use a ball nose endmill, plane selection YZ, circular interpolation. The toolpath will be a little long, but the bores will be as coaxial as possible, and you won't have to mess around dialing the part.

[NatFJ55]

Good suggestions.

I was leaning towards trying to bore it al the way through, but I may rethink it.